Process of and apparatus for rolling metallic disks



Nov. 16,1926. 1,606,903

. J. SMITH PROCESS OF AND APPARATUS FOR ROLLING METALLIC DISKS il p 4. 1920 3 Sheets-Shee t 1 WITNESSES: IIIVEIVTOR f0Jz21/ 71/. Smz'ifk,

BY W P im.

Nov. 16,1926. 1,606,903

J. W. SMITH PROCESS -05 AND APPARATUS FOR ROLLING METALLIC DISKS Fi e p 4. 1920 3 Sheets-Sheat 2 EC}. K

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Nov. 16 1926. 1,606,903

J. w. SMITH PROCESS OF AND APPARATUS FOR ROLLING METALLIC DISKS Filed Sept. 4, 1920 3 Sheets-Sheet 3 1516C IE W ill Z5 My. 1 m g 2Z5 2% 322 1 21 I IE: I 2

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Patented Nov. 16, 1926.

NII'EQ STATES JOHN W'. SMITH, OF PHILADELPHIA, PENNSYLVANIA, ASSIGNOR TO BUDD WHEEL COMPANY, OF PHILADELPHIA, PENNSYLVANIA, A CORPORATION OF PENNSYL- VANIA.

PROCESS OF AND APPARATUS FOR ROLLING METALLIC DISKS.

Application filed September 4, 1920. Serial No. 408,231.

I he invention relates more especially to a process of rolling steel disks such as are employed in the manufacture of vehicle wheels; and also to apparatus useful in the practice of the process.

As is well known, the use of a rolling operation has long been a common expedient in effecting refinement of metals to render them more homogeneous, and, as a consequence, more tenacious. The applicationof this principle to the rolling of disks, especially of the type wherein variations in cross sectional configuration are desired, has been heretofore extremely difficult of accomplishment on account of the tendency of the metal to buckle and thus set up internal shearing stresses which result ultimately in fracture r splitting, as the operation proceeds.

The object of my invention is to overcome these difliculties, and this I accomplish by so controlling the How of the metal as to effectan even distribution thereof during the entire rolling operation with a result that both the diameter and circumference of the blank are gradually increased in proper ratio,thus positively preventing any buckling or deformation such as above referred to.

One of the objects of my invention is to provide a process by means of which a disk of varying thi kness may be rolled from a blank of uniform thickness without any buckling or deformation of the finished disk.

Another object of my invention is to provide a process of rolling disks by means of which an improved surface may be given to the finished disk.

My improved process and apparatus will be better understood from the detailed description which follows,

In the accompanying drawings, Figs. I and II are respectively, a plan and cross sectional view of asheet metal blank such as I prefer to employ in rolling disks according to my improved process.

Fig. III is a view corresponding to Fig. II, showing an intermediate step in the process.

Fig. IV is a sectional view of the finished product.

Fig. V is a plan view of an apparatus, by aid of which my process may be conveniently practiced.

Fig. VI is a further illustration of the structure, shown in Fig. V, partly in side elevation and partly in longitudinal section.

Fig. VII is an illustration similar to Fig. VI, of a slightly modified form of apparatus.

In carrying out my improved process, I employ a circular blank, such as represented by the letter B in Figs. I and II, from which to roll the disk. This blank may be cut from a metal sheet or plate of uniform thickness, but this is not essential as my process may be carried out on a blank of varying cross-section. For instance, the blank may be a tapered disk which is subjected to my process for the purpose of improving its surface and changing the cross section. This blank is placed upon a suitable supporting element indicated in dotted lines at l in Fig. III, and subjected to a rolling operation by means of one or more rolls, fragments of which are shown in dotted lines at 2-2. These rolls are adapted to cooperate with the element 1 in rolling the interposed blank, and, it will be observed, are generally conical in form, except for a comparatively narrow tread 3, which is slightly rounded as at4. In actual practice, I prefer to employ two such rolls, and to arrange them to move radially outwardly at corresponding rates and in opposite directions with respect to the axis of the blank. The blank and the rolls 2 are relatively rotated in the course of the operation, and sufficient pressure is maintained between said rolls and the supporting element 1 to bring about the desired reduction of section in the finished product. By reason of the narrow tread, it will be observed that the area of contact between the rolls and the surface of the blank is exceedingly small, so that the metal is very gradually displaced, and thus free to adjust itself in accordance with the automatic expansion of a blank. As a consequence, both the diameter and the circumference of the blank are gradually and constantly increased in the proper ratio, thereby obviating any tendency to buckle or fracture. During the rolling operation, the conical surfaces of the rolls serve, after the manner suggested in Fig, III, to prevent the edge of the plate from turning or dishing too abruptly upward (as would otherwise naturally be the case under the forced displacement of the metal), and thus tend to facilitate further progress of the rolls radially of the supporting element 1. The slight rounding at of the roll treads assists the fiow of the metal, and also prevents the formation of a sharp angle at the region of divergence of the dished portion of the blank, thus obviating any possibility of fracture which might otherwise result.

When a disk of tapered cross section is desired, such as shown in Fig. IV, this may be obtained either by guiding or directing the radial movement of the forging rolls 2 at a slight angle (corresponding to that of the degree of attenuation desired) to the surface of the supporting element 1, or by providing said element with an inclined forming or die surface, as indicated at 5 in Fig. III, and confining the movement of the rolls definitely to a direction parallel to the plane of the supporting element. In either event, the metal of the blank will gradually be displaced radially, as previously pointed out. Furthermore, from the above, it will be obvious that any desired cross sectional configuration of the disk may be obtained by varying the pressure between the supporting element and the rolls at different times during the forming operation, or by providing die surfaces in the supporting element by which such configurations may be definitely produced.

Referring now to the apparatus shown in Figs. V and VI, the corresponding elements described in the previous figures have been designated by similar reference characters,- i. e., the supporting element by the numeral 1, the rolls at 22, and the blank by the letter and so on. In this structure the supporting element 1 is shown as having the form of a turn table to which the blank B is secured (in cases in which said blank may-,be provided with a central aperture) by means of a. removable clamp screw 6. The turn table 1 has a coaxial depending extension or stem 7, which is rotatably supported in bearings housed within a central enlargement 8 of a frame 9. The upper end of the stem 7 runs in a ball bearing 10, while its lower reduced end is supported in a thrust bearing comprising a sleeve 11,a disk 12 (serving as an abutment for a should-ered flange 13 on said ste1n),and a thrust washer 1st interposed between the sleeve and the disk. Said sleeve is threaded within the enlargement 8, so as to permit vertical adjustment of the turn table for a purpose which will be later set forth. In order that the extent of such adjustment may be predetermined, the protruding end of the sleeve 11 is provided with -a pointer 15 adapted for coordination with scale graduations on a boss 16 of the enlargement 8. R0- tation of the sleeve 11 may be effected by means of a handle 17, capable of being inserted into any one of anumber-of holes 18 in said sleeve. As a means for continuously rotating the turn table 1, I have attached to the lower end of the stem 7, a pulley 19 which may be driven from any convenient source of power. The rolls 22, as previously described, are adapted to be moved radially outward in opposite directions with respect to the axis of the table 1. Such guidance of the rolls is effected by means of bars 2020 (supported by posts 2'i21 of the frame 8), which serve as slideways for the carriages 2222 in which the rolls are mounted. As ameans for bringing about simultaneous and uniform relative shifting of the rolls with respect to the table axis, I have shown a feed screw 25, threaded left-handed at one end, and righthanded at the other, said screw being rotatable by means of a handle 26. The turn table 1 illustrated in this connection is of the forming die type which has been previously described, the inclined surface being represented as before by the numeral 5.

In beginning the operation, the rolls 2 are first moved inwardly, toward the center of the table, as far as they will go; the sleeve 11 is sufiiciently lowered by turning the same by means of the handle 17 to permit the insertion of the blank B beneath the rolls 22; and the blank is secured by means of the clamp screw 6. The table is then raised and set according to the scale graduations upon the boss 16, which are so calibrated that slight variations within a few thousandths of an inch may be obtained in the thickness of the disk. The table is then set in motion and the rolls 2 gradually moved outward in a direction away from the axis of the turn table by rotating the crank handle 26 until the disk has been completely rolled, the finished product thus having the cross sectional configuration shown in Fig. IV.

Referring now to the modified structure shown in Fig. VII, it will be noted that the same is generally similar to the form previously described, except that in this instance, the function of supporting the blank B during the rolling operation is relegated to paired roller cones s0:5o, of which there may be one or more sets. The roller cones of each such pair have their axes set at like inclinations atopposite Sides of the e t a centre of the Structure, and

are adapted to be driven simultaneously at uniform speed by any suitable means capable of attachment to the protruding ends of their shanks 3131. In order that the roller cones may be adjusted with respect to the forging rolls 22, the housing 32 in which the shanks 8131 are journalled, is carried upon a shoulder 33 of a sleeve 34, which is screw threaded, as indicated at 35, into the main frame 36 rotatable in the same manner as the sleeve 11 of the first described embodiment of my invention. In the sleeve 3st is journalled a vertical shaft 37 formed with a shouldered flange 38, which rests upon a thrust washer 39 at the upper end of the sleeve. The blank B is secured in the structure by means of a removable clamp screw or key ll) which is threaded into the top of the shaft 37. By this construction, said shaft is free to revolve under motion induced by the blank B in rotating. For rolling disks of tapered cross section, the slope of the surfaces of the roller cones 30 with respect to the path of movement of the rolls 2, 2, is made such as to determine the attenuation as desired. The mounting of the rolls 22, is in this case, exactly the same as in the first instance, so that further description thereof would be mere superfluous repetition. The operation of the machine is as follows:

The table 1, having been lowered and the blank B clamped in place thereon, the table is then raised until the blank engages the rolls with suflicient pressure to cause a decrease in thickness of the metal at the points of contact with the rolls. The table is driven through the pulley 19 so that it revolves and causes the blank to rotate with it. The reduction in thickness of the blank due to the pressure between the rolls and the table, causes the outer portions of the blank to flare upwardly away from the table, forming a flaring peripheral flange. The rolls are traversed radially toward the outer edge of the table by the feed screw, 25, as the table rotates.

The portions. 4, of the rolls act on the flaring flange. of the blank, near the base of such flange. and draw the metal, after the manner of a metal-spinning tool. The metal of the blank is caused to flow in the desired direction to decrease the thickness and increase the diameter of the blank by the simultaneous rolling and spinning action of the rolls. As the rolls approach the periphery of the blank, due. to the feeding motion given to them by the feed-screw, 25, the flaring flange, produced by the pressure of the rolls, is gradually decreased in width until it is entirely consumed,jpassing under rolls 2, and the completed disk lies fiat on the table, 5. The cross-section of the completed disk will be determined by the contour of the table, 5. If the table be a plaiie surface parallel to the plane surface defined by the axes of rolls, 2, the resulting disk will be of uniform cross-section. Usually, however, it is desired to produce a tapered disk by this process and the taper of the disk will be determined by the slightly conical or concave shape given to the surface of table, 1. Of course, the process may be interrupted. be fore the rolls reach the periphery of the blank, in which event the resulting product will have a peripheral flange. which is not reduced in thickness. This may be desirable in certain cases in which one wishes to produce disks having a peripheral flange.

The blank may be worked either hot or cold, depending largely upon the extent of the reduction to be effected. This process, as indicated above, may be applied to tapered disks already formed to improve the surface thereof. such tapered disks are rolled cold by my process, the flow of metal incident to the reduction in thickness caused by the rolling gives a surface to the finished disk which is particularly good for receiving paint or enamel.

I am aware. that the particular embodiment of my process and apparatus, described herein, is susceptible of considerable modification and change without departing from the spirit of my invention and, therefore, I desire to claim my invention broadly, as indicated by the appended claims.

Having thus described my invention, I claim:

1. The process of making a thin disk of tapering cross section from a sheet metal blank of fleven thickness which consists in concurrently" pinningfthe metal of the blank radially outward'to 'a progressively increasing degree and rolling circumferentially to a correspondingly diminishing thickness the metal so spun.

2. The process of making a thin disk of tapering cross section from a sheet metal blank of even thickness, which consists in dishing the blank to concavo-convex forma tion and effecting a redistribution of the surface metal solely on the concave side to reduce the same to a plane surface.

3. The process of making a thin disk of tapering cross section from a sheet metal disk blank of even thickness, which consists in converting the blank to concavo-convex formation, and operating on the concave side to reduce the same to a plane surface with out altering the convex side, whereby the circumference of the blank is increased and the gauge reduced uniformly toward the periphery.

4. The process of rolling a thin disk of tapering cross section from a sheet metal disk blank of even thickness, which consists in converting the blank to concavo-convex formation, and rolling the concave side to a I have found that, when l Hil ill

plane surface without changing the curvature of the convex side, whereby the circumference of the blank is increased and the thickness of the metal reduced uniformly to- *a rd the periphery.

5. The process of rolling disks consisting in rotatably supporting a sheet metal blank, applying one or more rolls under pressure to the exposed surface of said blank, and, simultaneously, rotating the blank and shifting the roll or rolls radially outward with respect to the blank.

6. The process of rolling tapered disks consisting in supporting a sheet metal disk blank of even thickness on a surface designed to impart a curvature to the contacting face of the blank, applying to the exposed face of the blank a rolling surface designed to exert pressure upon relatively small areas of the blank at a time, and shifting said rollingsurface relative to the blank in a flat plane to effect the formation of a plane surface upon the exposed face of the blank.

7. The process of forming a disk of tapering cross section from a sheet metal disk blank of uniform cross section consisting in exerting pressure on portions of the blank in an increasing degree toward the periphery to decrease the thickness thereof and form a flaring peripheral flange on the blank, s inning iheametal o f said fiange radially outward and, simultanhbiil'iiclling the blliiik circumferentially.

8. The process of forming a tapered disk from a sheet metal disk blank of uniform thickness consisting in exerting a uniformly increasing rolling pressure on said blank along a spiral path from the central portion of the blank to the periphery and, simultaneously, spinning radially outward the flaring flange generated by the displacement of metal due to said rolling pressure.

9. An apparatus of the character described comprising a spinning form affording a support for the blank, and a forming tool engaging the blank to spin the same to configuration corresponding to the form, and means supporting the tool and movable in a plane non-conformable with the profile of the form so as to effect variations in the gauge of the product.

10. An apparatus for producing disks of tapered cross section from sheet metal blanks comprising a spinning form of desired profile affording a support for the blank, a forming tool engaging the exposed surface of the blank to spin the same substantially to the profile of the form and means supporting the tool and movable in a plane slightly out of conformity with the profile of the form so as to effect a gradual reduction in the gauge of the material toward the periphery.

11. The process of making tapered disks which consists in rolling a sheet metal blank of even thickness along a spiral line running from the center to the periphery and, simultaneously, reducing the flaring flange generated by such rolling.

12. Apparatus for rolling disks comprising means for revolubly support-ing the disk at one side; a roll mounted to roll and revolve circumferentially of the disk at the other side thereof; and means for progressively shifting the revolving roll radially outward from the centre of the disk with gradual approach closer and closer to said support; said roll having a leading conical spinning face and an adjacent concentric rolling face.

13. An apparatus for rolling disks comprising means for supporting a circular blank; a cooperating roll, and means for progressively shifting said roll across the supported portion of the blank in a direction radially outward from the axis of the latter to gradually displace the metal of the same and decrease its thickness.

14:. An apparatus for rolling disks comprising means for supporting a circular blank, a cooperating roll engaging the blank, means for progressively shifting said roll radially outward from the axis of the blank to gradually spin the metal of the same outward and reduce its thickness, and means for adjusting said supporting means and roll relatively to each other to vary the thickness of the disk.

15. An apparatus for making disks of tapered cross section comprising means for supporting a circular blank; and a cooperative roll capable of being shifted across the surface of the supported blank radially outwardly from the centre of the latter and simultaneously at a slight relative inclination thereto, to gradually spin the metal of the disk outward and progressively attenuate it.

16. An apparatus for rolling disks of t...- pered cross section comprising a turn table for supporting a circular blank, said table having an inclined forming surface by which the angle of the desired attenuation is determined; a roll; and means for shifting said roll across the surface of the blank radially outward from the centre of the latter, the roll thus cooperating with the forming surface of the t urn table to gradually spin the metal of the lilafik putward and progres sively attenuate it more and more.

17. An apparatus for rolling disks com prising a turn table for supporting a circular blank; a pair of cooperating rolls capable of being shifted in opposite radial directions across the surface of the supported blank outward from its centre; and means for effecting simultaneous and relatively uniform shifting of said rolls.

18. The process of rolling disks comprising subjecting a suitably supported metal. blank to a rolling pressure and, simultane ously, spinning radially outward the flange produced on such blank by said rolling pressure.

19. The method of rolling tapered disks comprising clamping a blank to and with one side supported by a rotating platen, then projecting against the inner portion one or more narrow faccd rolls, and while said blank is rotating on said platen; traversing said roll or rolls toward the circumference, thereby compacting, thinning and increasing the diameter of the blank to form a disk.

20. The method of rolling shaped or tapered disks which consists in clamping a blank to a rotatable platen which is dished or formed to conform to the contour of one side of a finished disk, then rotating said platen and forcibly projecting against the inner portions of the blank one or more narrow faced rolls and gradually traversing said roll or rolls over the blank to or near the periphery thereof thereby compacting, thinning and increasing the diameter thereof to form a disk.

21. The method of rolling shaped or tapered disks which consists in clamping a blank to a rotatable platen which is dished or formed to conform to the contour of one side of the finished disk, then rotating said platen and forcibly projecting against the inner portion of the blank one or more narrow faced rolls to cause the outer portion of the blank to curl away from the platen while traversing the rolls 'over the blank.

22. The process of rolling a tapered disk which comprises clamping a blank on a rotating platen and bringing the blank into contact with a roll which traverses the blank as it rotates with the platen, thereby shaping and expanding the blank as desired.

23. The method of rolling a tapered disk which comprises clamping a blank on a rotating platen shaped to conform with the desired section of disk and bringing the blank into contact with a pair of rolls which are retracted outwardly from the center of the blank as the blank rotates below the rolls thereby expanding and shaping the blank as desired.

24. A machine of the class described comprising a support for the blank to be rolled and a roll carrying frame relatively movable toward and away from each other; a pair of rolls carried by the frame, one at each side of the center of the blank; means for imparting relative movement to the frame and support; and means for moving the rolls oppositely and radially of the blank in a progressive manner while operating on the blank to continually effect changes therein.

25. A machine of the the class described comprising a support for the blank to be rolled and a roll carrying frame relatively movable toward and away from each other; a pair of rolls carried by the frame, one located at each side of the center of the blank; means for imparting relative movement to the frame and support and for urging them together under pressure; and means for .moving the rolls oppositely and radially of the blank in a progressive manner while operating on the blank to continually effect changes of form therein.

26. The method of making tapered wheel disks which consists in spinning and rolling a metal blank in spiral progression from the central portion outwardly to progressively reduce its thickness and finish its surfaces, the while confining the finished sur faces to flat form, and converging the finished surfaces thereof as the spinning and rolling progress.

27. The method of making flat and fa pered wheel disks which consists in spinning and rolling a blank to increasing degree in spiral progression to taper the same and in a plane at substantially right angles to the axis of the flat blank whereby the finished disk becomes of flat form.

28. The method of making flat and radially tapered wheel disks which consists in first taking a flat metal blank of substantially uniform thickness, supporting the blank and spinning and rolling it on developed surfaces comprehending between them the form of the finished disk and together extending, substantially at right angles to the. axis of the disk, and progressing the spinning and rolling operations spirally from the central portion outwardly of the blank.

29. An apparatus of the character described comprising a rotatable table having a concaved blank-supporting surface, and rolls mounted on axes transverse to the table axis and traversible radially of the table from the center outwardly in contact with a blank being operated upon along a rectilinear path.

30.111 a machine of the character described the combination of a support for the blank to be rolled and a cooperating roll bodily rotatable relative to one another, approach and separation mechanism to move the roll and the support toward and from each other to project the roll against the blank and to permit the insertion of a fresh blank between the roll and its support and also to permit the thickness of the rolled blank to be varied, and traversing mechanism for causing relative movement of the roll and support to shift the roll crosswise of the support to roll a blank thereon and to return the roll to initial position.

31. A machine of the character described, a rotatable platen for supporting a blank in a horizontal plane, a roll support having a relative movement of approach and separation with respect to said blank support, rolls carried by said support on opposite sides of the platen axis, and transversable radially of said platen, means for simultaneously traversing said rolls, and means for caus ng said relative movement of approach and separation.

32. A machine of the class described comprising a support for the blank to be rolled and a roll carriage relatively movable toward or away from one another, and transversely of each other, a roll on said carriage m for cooperating with the said support to roll a blank thereon, and means for relatively moving said carriage and support to cause the approach or separation of the support and roll and the relative transverse movement of said parts, as and for the purpose specified.

In testimony whereof, I have hereunto signed my name at Philadelphia, Pennsylvania, this 26th day of August, 1920.

JOHN W. SMITH. 

